WORK INSTRUCTION READ FIRST. IF IN DOUBT

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Marjory Strickland
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How to remove the side lift up window locks and replace them with newly supplied keyed a like

1 WORK INSTRUCTION PAGE 1 OF 9 FIELD CHANGE INSTRUCTION : TO CHANGE A BACK DOOR AND SIDE LIFT PROCEDURE: Step 1. How to remove and replace the rear door of a canopy. Step 2. How to remove the side lift up window locks and replace them with newly supplied keyed a like versions to match the new back door. ENVIRONMENTAL, OH&S ISSUES : 2 people required for removing and replacing the back door.

2 PAGE 2 OF 8 EQUIPMENT, MATERIALS & TOOLS REQUIRED 13 mm ring spanner, 29 mm ring spanner or socket, a 2.5 mm Allen key, torque wrench capable of 6 nm. Small screw driver and a soft mallet.

WORK INSTRUCTION PAGE 3 of 8 FIELD CHANGE INSTRUCTION : TO CHANGE A BACK DOOR AND SIDE LIFT 1 1.

the ball joint on the rear door hinges. 1.

flat blade screw driver. 2. Second man now takes the weight of the door when both strut mounts have been removed. 3 1.

3 WORK INSTRUCTION PAGE 3 of 8 FIELD CHANGE INSTRUCTION : TO CHANGE A BACK DOOR AND SIDE LIFT 1 1. Open the back door to access both the gas strut mounts on door interior and the hinges attached to the inside glass surface. 2. You will need two people now, one person supports the back door while the other person detaches the strut end caps from the ball joint on the rear door hinges Release the gas strut bracket, slide the ring clip up the ball strut mount housing to allow removal using a fine tipped flat blade screw driver. 2. Second man now takes the weight of the door when both strut mounts have been removed Removing hinges requires a 13 mm ring spanner, take care that the nuts and hinge pin retaining clip, the washers and spring washers are kept. 2. Take not of the hinge pin retaining clip assembly, reassemble in the same order later onto new glass door 4 Prepare the hinges for mounting the rear door on, by elevating them to a horizontal position to allow for easy placement of the new rear door. Undo as indicated by red arrows Hinge pin retainer clip sits behind the flat head of the hinge pin Remove previous glass to somewhere safe. Then retrieve the new glass ready for instillation

PAGE 4 OF 8 UP WINDOW LOCK SET WITH KEYED A LIKE LOCKS ON A CANOPY. 5 1.

Place the outer stud plate and gasket on the outside of the glass so the stud threads come through completely. 6 1.

Place the washer and hinge pin retainer clip onto the studs followed by the flat washers, spring washers and nuts.

NOTE the pressed center hole detail in the gasket from the previous hinge as a line up reference. 7 1.

4 PAGE 4 OF 8 UP WINDOW LOCK SET WITH KEYED A LIKE LOCKS ON A CANOPY Place the rubber gaskets into the holes for each corresponding hinge mount on the inside of the glass. 2. Place the outer stud plate and gasket on the outside of the glass so the stud threads come through completely Locate the glass over stainless upper hinge plate that is attached to the canopy shell. 2 people are required here. 2. Bring the glass together with the outer stud plate, and place the threaded studs through the hinge plate. 3. Place the washer and hinge pin retainer clip onto the studs followed by the flat washers, spring washers and nuts. When locating glass and gasket onto hinge/canopy body. NOTE the pressed center hole detail in the gasket from the previous hinge as a line up reference Hand tighten initially the 4 x 13 mm nuts, then use a ring spanner to tighten until spring washers are flat and ensure the hinge pin retaining clip is reinstalled. 2. Check the gasket and hinge alignment is good. 3. If correct proceed to tightening with the torque wrench set to 6 Nm. 8 Re-attached the gas struts to the rear door WITH THE CYLINDER END TO THE DOOR FRAME AND THE ROD END TO THE GLASS. Slide clips into place, check struts are firmly locked by pulling on the shaft.

PAGE 5 of 8 9 1. With the vehicle tailgate open, and viewing from inside, close the door slowly to check slam latch strikers (left and right) alignment to door rotary latch. 2.

If striker doesn t engage the rotary latch 2. Climb into the interior of vehicle tub and check the misalignment position. 3. If the strikers are only a few mm out of alignment.

5 PAGE 5 of With the vehicle tailgate open, and viewing from inside, close the door slowly to check slam latch strikers (left and right) alignment to door rotary latch. 2. If good, check the locks work. Then move to stage 2 Fitting the side window locks 3. If striker doesn t engage the rotary latch, then continue with Step If striker doesn t engage the rotary latch 2. Climb into the interior of vehicle tub and check the misalignment position. 3. If the strikers are only a few mm out of alignment. A soft mallet, or an adjustable spanner closed over the striker loop can be used to adjust it up or down vertically. Do this carefully by bending or hammering the end of the striker to move it into position in line with the rotary latch housing. 4. After adjustment check the door closes fully and locks with strikers adjusted all the way on their slots to the rear of the vehicle. Check strikers are engaged to the second stage of locking on the rotary latch. 5. If required the covers over the rear door lock mechanism can be remove to allow tuning of the locks. Behind the center interior door handle cover, you can wind in or out the pull rods, if the door lock will not open or release the rotary latches properly. 6. Close door after adjustment and check, re adjust as necessary. Keep tailgate down for easy access. 7. Re-install the covers on the lock mechanism. Be careful not to strip the threads when screwing covers back on. Next stage move to the side window lock change. Check hinge and gasket position above is still aligned. Before adjusting striker positions with mallet.

Then remove the striker careful so as not to loose the grub screw. 13 To remove the gas struts on window brackets.

6 PAGE 6 of 8 REPLACING THE 2 SIDE WINDOW LOCKS. 11 Working from the inside of the lift up window, access the cam on the lock. 12 Using a 2.5 mm Allen key remove the grub screw from the upper end of the striker so you can remove it. Then remove the striker careful so as not to loose the grub screw. 13 To remove the gas struts on window brackets. Use the same procedure as removing the strut brackets on the back door. With a flat blade screw driver. 14 Next remove the black 29 mm locking nut on the back of the bracket.

PAGE 7 of 8 15 After removing the nut, remove the washer and locate for later use if

Remove the lock body from the outside of the window, by pulling on the T Handle to extract

Be careful not to loose the central rubber washer between the bracket and glass NOTE:

as a key way. Be sure to line the locks up facing the right way.

7 PAGE 7 of 8 15 After removing the nut, remove the washer and locate for later use if necessary, new lock set kit has a full set of gaskets as well Remove the lock body from the outside of the window, by pulling on the T Handle to extract it. 2. Be careful not to loose the central rubber washer between the bracket and glass NOTE: There is a rubber washer between the lock mounting bracket and the glass surface Locate the new lock sets. 2. Note the inside hole of the bracket that the lock goes through has two flat faces that act as a key way. Be sure to line the locks up facing the right way. Refer to step 19 if unsure how to do. 3. Continue placement and locate by lining up the lock body to the flat faces in the hole of the bracket then 18 Before re assembling the new lock into the hole. Check the lock body is facing the right way. HORIZONTAL IS LOCKED POSITION- UNLOCK TURN CLOCKWISE

PAGE 8 OF 8 19 1. Before re assembling the new lock into the hole. Check the lock body is facing the right way. 2.

8 PAGE 8 OF Before re assembling the new lock into the hole. Check the lock body is facing the right way. 2. For the LHS window lock the larger side of the handle should face out wards from the window center (Striker engaged position 6:00 o'clock). When the handle is turned it should rotate the striker from 6 o'clock to 9:00 o'clock in a clockwise direction. 3. On the right hand side the T handle should be the same set up except larger end will face into centre of window. 20 Next Tighten up the 29 mm locking nut on the lock body making sure the plastic washer is underneath the nut and the rubber washer is between the glass and bracket NOTE: There is a rubber washer between the lock mounting bracket and the glass surface 21 Re-install the internal cam and adjust the position of the cam on the inside until happy with the lock closing full on rotation 22 Reinstall gas struts with the cylinder end to the window frame and the rod end to the glass Test operation of the window and locking, if difficult to turn locks loosen the grub screws on the lock cam and move the position further out on the shaft and re-tighten again in position. Add a drop of Loctite 277 to grub screws on cams.

MAZDA BT-50 (October 2011 Production Onwards) 1 & 3 PIECE HARD TONNEAU REMOTE LOCKING KIT INSTALLATION INSTRUCTIONS

MAZDA BT-50 (October 2011 Production Onwards) 1 & 3 PIECE HARD TONNEAU REMOTE LOCKING KIT INSTALLATION INSTRUCTIONS MAZDA BT-50 (October 0 Production Onwards) & 3 PIECE HARD TONNEAU REMOTE LOCKING KIT INSTALLATION INSTRUCTIONS Installation Time: Approx. 0 Minutes Care Instructions: Clean Tonneau Cover with a mild detergent